Abrasive preforms and manufacture and use methods

ABSTRACT

A method for applying an abrasive comprises: applying, to a substrate, the integral combination of: a self-braze material; and an abrasive embedded in the self-braze material; and securing the combination to the substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation in part of U.S. patent application Ser. No.14/755,350, filed Jun. 30, 2015, and entitled “Abrasive Preforms andManufacture and Use Methods”, published Jan. 7, 2016 as Publication No.2016/0003066A1, which claims benefit of U.S. Patent Application No.62/020,041, filed Jul. 2, 2014, and entitled “Abrasive Preforms andManufacture and Use Methods”, the disclosures of which applications andpublication are incorporated by reference herein in their entireties asif set forth at length. This is a continuation in part of U.S. patentapplication Ser. No. 14/750,415, filed Jun. 25, 2015, and entitled“Abrasive Coating and Manufacture and Use Methods”, published Jan. 7,2016 as Publication No. 2016/0003065A1, which claims benefit of U.S.Patent Application No. 62/020,038, filed Jul. 2, 2014, and entitled“Abrasive Coating and Manufacture and Use Methods”, the disclosures ofwhich applications and publication are incorporated by reference hereinin their entireties as if set forth at length. This is a continuation inpart of U.S. patent application Ser. No. 14/750,324, filed Jun. 25,2015, and entitled “Abrasive Coating and Manufacture and Use Methods”,published Jan. 7, 2016 as Publication No. 2016/0003064A1, which claimsbenefit of U.S. Patent Application No. 62/020,036, filed Jul. 2, 2014,and entitled “Abrasive Coating and Manufacture and Use Methods”, thedisclosures of which applications and publication are incorporated byreference herein in their entireties as if set forth at length.

BACKGROUND

The disclosure relates to abrasive coatings. More particularly, thedisclosure relates to pre-formed abrasive coatings which may be appliedto a substrate.

Gas turbine engines may have one or more nested spools of compressorsections and turbine sections co-rotating about an engine axis. Anexemplary two-spool engine has: a low speed/pressure spool comprising alow speed/pressure compressor (LPC) and a low speed/pressure turbine(LPT); and a high speed/pressure spool comprising a high speed/pressurecompressor (HPC) and a high speed/pressure turbine (HPT). The coreflowpath of the engine passes air sequentially through the LPC and HPCto the combustor where it mixes with fuel and combusts. Combustion gasesthen proceed further downstream along the core flowpath through the HPTand LPT. Thus, the turbine sections may drive the rotation of theirrespective associated compressor sections. Optionally, one or more fansections may be driven by the LPT or another turbine section. The fansections drive air along a bypass flowpath, bypassing the core toproduce additional thrust.

The individual compressor and turbine sections may be centrifugal oraxial in configuration. In exemplary axial configurations, each sectionmay have a number of stages. Each stage comprises an annular array orrow (stage) of rotor blades. The blade stage may have an associatedadjacent stage of stator vane airfoils. The airfoils are shaped to turn,accelerate and compress the working fluid flow in the compressor, and togenerate lift for conversion to rotational energy in the turbine.

In a number of locations it may be desired to minimize clearance betweenrelatively rotating components. A main example is the clearance betweenblade tips and the adjacent inner diameter (ID) surface of non-rotatingstructure. This ID surface is often formed by the ID surfaces of acircumferential array of blade outer air seal (BOAS) segments. The IDsurface may be formed by an abradable ceramic coating on the ID surfaceof a metallic substrate of the BOAS segments. To interface with theabradable coating, the blade tips may bear an abrasive. The abrasivefunctions to abrade the abradable coating and provide a wear-in to a lowradial clearance value between blade and BOAS. Low clearance means lowblow-by of gas between tip and BOAS and thus high efficiency.

Many methods have been proposed for applying abrasive to blade tips.These include direct plating and direct spraying methods. Additionally,use of pre-formed abrasive has been proposed. U.S. Pat. No. 7,063,250 ofOhara et al., issued Jun. 20, 2006, discloses forming a squealer tippreform by plating an MCrAlY matrix and cubic boron nitride (CBN)abrasive to a brazing filler sheet. The preform is then brazed to thetip of a main airfoil substrate. U.S. Pat. No. 8,616,847 of Allen,issued Dec. 31, 2013, discloses forming a squealer tip preform byplating an MCrAlY matrix and cubic boron nitride (CBN) abrasive to asquealer tip preform. The preform is then brazed to the tip of a mainairfoil substrate.

SUMMARY

One aspect of the disclosure involves a method for applying an abrasive.The method comprises: applying, to a substrate, the integral combinationof a self-braze material and an abrasive embedded in the self-brazematerial; and securing the combination to the substrate.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the securing comprisingheating to cause the self-braze material to braze to the substrate or anintervening component.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the applying comprisingapplying an assembly of the combination and at least one additionalbraze material layer, said additional braze material layer lackingabrasive.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the assembly furthercomprising a cast intermediate layer.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the self-braze material andthe at least one additional braze material layer each comprising amixture of alloys of different melting points.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the securing comprises heatingand leaves at least a portion of the self-braze material with acomposition comprising, in weight percent: cobalt 2.5-13.5; chromium12-27; aluminum 5-7; yttrium 0.0-1.0; hafnium 0.0-1.0; silicon 1.0-3.0;tantalum 0.0-4.5; tungsten 0.0-6.5; rhenium 0.0-2.0; molybdenum 0.1-1.0;and the balance nickel.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include said portion of the self-brazematerial having said composition comprising, in weight percent: cobalt2.5-13.5; chromium 12-27; aluminum 5-7; yttrium 0.0-1.0; hafnium0.0-1.0; silicon 1.0-3.0; tantalum 2.0-4.5; tungsten 2.0-6.5; rhenium0.0-2.0; molybdenum 0.1-1.0; and the balance nickel.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include said composition having nomore than 1.0 weight percent of any other individual element.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include said composition having nomore than 3.0 weight percent of all other individual elements combined.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the abrasive comprising cubicboron nitride.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include a weight ratio of the abrasiveto the self-braze material being from 1:2 to 2:1.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include a weight ratio of the abrasiveto the self-braze material being from 1:2 to 2:1.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the self-braze materialcomprising a sintered mixture of: at least one first alloy of lowmelting point relative to the substrate; and at least one second alloyof high melting point relative to the first alloy.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the combination comprisingsaid abrasive in a matrix of: at least one first alloy of low meltingpoint relative to the substrate; and at least one second alloy of highmelting point relative to the first alloy.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include: the at least one first alloycomprising about 21.25-22.75 chromium, about 5.7-6.3 aluminum, about11.5-12.5 cobalt, about 5.7-6.3 silicon, boron in an amount no greaterthan 1.0 weight percent, and a balance of nickel plus impurities if any;and the at least one second alloy comprising about 4.75-10.5 chromium,about 5.5-6.7 aluminum, up to about 13 weight percent cobalt, about3.75-9.0 tantalum, about 1.3-2.25 molybdenum, about 3.0-6.8 tungsten,about 2.6-3.25 rhenium, up to about 0.02 boron, about 0.05-2.0 hafnium,up to about 0.14 carbon, up to about 0.35 zirconium, and a balance ofnickel plus impurities if any.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include a boron content of the firstalloy being at least 0.30 weight percent greater than a boron content,if any, of the second alloy.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include: the at least one first alloycomprising no more than 1.0 weight percent of any other individualelement; and the at least one second alloy comprising no more than 1.0weight percent of any other individual element.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the combination having acharacteristic thickness T₂ of 0.20-2.50 millimeters.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the applied combinationconsisting of the self-braze material and the abrasive.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include forming the combination by:mixing the abrasive and powders of at least two different alloys; andsintering the mixture.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the at least two differentalloys comprising: at least one first alloy of low melting pointrelative to the substrate; and at least one second alloy of high meltingpoint relative to the first alloy.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include an article formed by themethod.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the article being a turbineblade and wherein the combination is applied to a tip surface of anairfoil of the blade.

Another aspect of the disclosure involves an article comprising: ametallic substrate; and a layer secured to the substrate and atcomprising a matrix material least partially embedding an abrasive. Atleast a portion of the matrix material has a composition comprising, inweight percent: cobalt 2.5-13.5; chromium 12-27; aluminum 5-7; yttrium0.0-1.0; hafnium 0.0-1.0; silicon 1.0-3.0; tantalum 0.0-4.5; tungsten0.0-6.5; rhenium 0.0-2.0; molybdenum 0.1-1.0; and the balance nickelplus impurities, if any.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the article being a turbineblade and the material being along a tip surface of an airfoil of theblade.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the layer being directlybonded to the substrate.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include a cast layer interveningbetween the layer and the substrate.

Another aspect of the disclosure involves a braze preform comprising theintegral combination of: a self-braze material; and an abrasive embeddedin the self-braze material.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the self-braze materialcomprising a sintered mixture of: at least one first alloy; and at leastone second alloy of high melting point relative to the first alloy.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include an additional braze materiallayer without abrasive.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include a Ni-based superalloy layerbetween the additional braze material layer and the combination.

A further embodiment of any of the foregoing embodiments mayadditionally and/or alternatively include the Ni-based superalloy layerbeing a cast layer.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features, objects, andadvantages will be apparent from the description and drawings, and fromthe claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-section of an abrasive preform exploded awayfrom a substrate to which it is being applied.

FIG. 2 is a schematic cross-section of a second abrasive preformexploded away from a substrate to which it is being applied.

FIG. 3 is a schematic cross-section of a third abrasive preform explodedaway from a substrate to which it is being applied.

FIG. 4 illustrates an example of self-braze alloy composition comprisinga blend of a low melting point alloy and a high melting point alloy.

FIG. 5 is a schematic cross-section of a fourth abrasive preformexploded away from a substrate to which it is being applied.

FIG. 6 is a schematic cross-section of a fifth abrasive preform explodedaway from a substrate to which it is being applied.

Like reference numbers and designations in the various drawings indicatelike elements.

DETAILED DESCRIPTION

FIG. 1 shows an abrasive preform 20. The preform may have a planform(footprint) cut to correspond to the area of a surface 22 substrate 24to which it is to be applied. Exemplary substrate surfaces are tipsurfaces of airfoils of turbine blades for installation in gas turbineengines.

The preform has a layer 30 having an inboard surface or face 32 and anoutboard surface or face 34. The layer comprises abrasive particles 42at least partially embedded in a matrix 40.

The layer thickness is shown as an essentially constant T₁. Measuredthickness may be a mean, median, or modal value. Exemplary T₁ is 0.25mm, more broadly 0.20-2.5 mm or 0.20-1.0 mm. Such thickness T₁ may bechosen so as to bond to the substrate and provide environmentalprotection. Thicker values may serve for dimensional restoration (e.g.,when tip substrate is worn).

The exemplary turbine blade substrate is a nickel-based superalloy, moreparticularly, having a single crystal (SX) structure.

The matrix 40 comprises an oxidation-resistant braze material. It iscapable of self-brazing to the substrate. For self-brazing, it comprisesa mixture of alloys of at least two different compositions. At least oneof the alloys is a relatively low melting point (low melt) alloy and atleast one of the alloys is a relatively high melting point (high melt)alloy. These alloys may themselves be nickel-based superalloys. The lowmelt alloy may comprise a relatively higher content of one or moreelements acting as melting point suppressants/depressants than does thehigh melt alloy. U.S. Pat. No. 8,075,662 (the '662 patent) of Minor etal., issued Dec. 13, 2011, the disclosure of which patent isincorporated by reference herein in its entirety as if set forth atlength, discloses exemplary braze material formed of a mixture ofpowders of differing composition. FIG. 4 shows the self-braze alloycomposition 200 including a blend 202 of a high melt alloy 204 and a lowmelt alloy 206. The high melt alloy 204 and the low melt alloy 206 areschematically shown as powders.

From the '662 patent, an exemplary high melting point alloy comprises,in weight percent, about 4.75-10.5 chromium, about 5.5-6.7 aluminum, upto about 13 weight percent cobalt, about 3.75-9.0 tantalum, about1.3-2.25 molybdenum, about 3.0-6.8 tungsten, about 2.6-3.25 rhenium, upto about 0.02 boron, about 0.05-2.0 hafnium, up to about 0.14 carbon, upto about 0.35 zirconium, and a balance of nickel. Other elements may bepresent in impurity amounts (e.g., typically not more than 1.0 weightpercent each and 3.0 weight percent aggregate). The term “about” as usedin this description relative to compositions or other values refers topossible variation in the given value, such as normally acceptedvariations or tolerances in the art.

Similarly, an exemplary corresponding low melting point alloy comprisesabout 21.25-22.75 chromium, about 5.7-6.3 aluminum, about 11.5-12.5cobalt, about 5.7-6.3 silicon, boron in an amount no greater than 1.0weight percent, and a balance of nickel. Other elements may be presentin impurity amounts (e.g., typically not more than 1.0 weight percenteach and 3.0 weight percent aggregate). In further examples said boronmay be present in 0.040-1.0 or 0.45-0.55 weight percent. Said boron maybe at least 0.40 weight percent greater than a boron content of the highmelting point alloy. An exemplary melting point of the high melt alloyis 2300° F. to 2500° F. (1260° C. to 1371° C.). An exemplary meltingpoint of the low melt alloy is 2050° F. to 2200° F. (1121° C. to 1204°C.). An exemplary difference in alloy melting points is at least 50° C.or an exemplary 50° C. to 150° C. or 60° C. to 120° C.

Table I below provides two examples of powder combinations. Theidentified final alloys reflect the nominal averaging of thecompositions based upon their weight percentages. As a practical matter,especially near the interfaces with the substrate and the matrix,inter-diffusion may cause departures from this theoretical value. Thefinal actual composition is, however, effective to provide desiredoxidation resistance.

TABLE I Exemplary Oxidation-Resistant Braze alloys % Ni Cr Al Co Ta Mo WRe Si B Hf Y High Melt #1 75 57 25 6 4 8 1 0.1 Lo Melt #l 25 53.5 22 612 6 0.5 Final Alloy #1 56.1 24.3 6.0 3.0 3.0 0.0 6.0 0.0 1.5 0.1 0.80.1 High Melt #2 55 63.3 7 6.2 7.5 6.5 1.5 5 3 0.15 Lo Melt #2 45 53.522 6 12 6 0.5 Final Alloy #2 58.9 13.8 6.1 9.5 3.6 0.8 2.8 1.7 2.7 0.20.1

Exemplary high melt to low melt weight ratios are between 50:50 and85:15, more particularly, 55:45 to 80:20.

The oxidation resistance comes from optimized percentages of Cr, Al, Si,Hf, and Y and effectively prevents oxidation at temperatures up to atleast 2150° F. (1177° C.) in engine operating conditions. Similarcompositions to the resulting final alloys are found in U.S. Pat. No.8,354,176 (the '176 patent) of Minor et al., issued Jan. 15, 2013, thedisclosure of which patent is incorporated by reference herein in itsentirety as if set forth at length. The '176 patent discloses anexemplary composition comprising, in weight percent, cobalt about2.5-13.5, chromium about 12-27, aluminum about 5-7, yttrium about0.0-1.0, hafnium about 0.0-1.0, silicon about 1.0-3.0, tantalum about0.0-4.5, tungsten about 0.0-6.5, rhenium about 0.0-2.0, molybdenum about0.1-1.0 and the balance nickel.

A more particular example is an exemplary composition comprising, inweight percent, cobalt 2.5-13.5, chromium 12-27, aluminum 5-7, yttrium0.0-1.0, hafnium 0.0-1.0, silicon 1.0-3.0, tantalum 2.0-4.5, tungsten2.0-6.5, rhenium 0.0-2.0, molybdenum 0.1-1.0 and the balance nickel.

Other elements may be present in impurity amounts (e.g., typically notmore than 1.0 weight percent each and 3.0 weight percent aggregate). Forexample, among these will likely be residual boron from the low meltalloy and elements diffused in from the matrix, abrasive, or substrate.Some of such diffused elements may be localized to transition regions,leaving a core region/layer closer to the nominal composition formed bythe two alloys.

Such material may have improved oxidation/corrosion resistance comparedwith a baseline standard second generation nickel-based superalloy(e.g., an alloy such as PWA1484 of United Technologies Corporation,Hartford Conn. and disclosed as the preferred example of U.S. Pat. No.4,719,080 (the '080 patent) of Duhl et al., issued Jan. 12, 1988, andentitled “Advanced high strength single crystal superalloycompositions”, the disclosure of which patent is incorporated byreference herein in its entirety as if set forth at length). Similarly,such baseline superalloy may have superior oxidation and corrosionresistance to conventional braze materials. Accordingly, comparison tosuch a baseline may be used to distinguish relative oxidation andcorrosion resistance.

In the '176 patent, an uncoated PWA 1484 substrate was used as thebaseline and assigned a relative absolute life of exactly 1. It andinventive coating compositions were subject to oxidation and corrosionresistance tests.

In the '176 patent, a burner rig oxidation test was performed. In thesetests, a coating was placed on a bar or coupon and mounted in a holder,in this case, a rotating spindle. The spindle rotated and was thrustinto a flame for a period of time and withdrawn for a much shorterperiod of time, and after a number of these repetitive cycles, theoxidation was measured. The flame is a combustion product comprised ofan ignited mixture of jet fuel and air. The speed of rotation of thespindle can vary from less than 400 rpm to more than 600 rpm. Thesamples were held in the flame for about 1 to 60 minutes, followed byremoval for 1 to 5 minutes. Results were reported as a relative life, oras a ratio of life measured of the specimen over the life measured of acontrol. All tests were run at 2150° F. (1177° F.), althoughtemperatures between 1800° F. (980° C.) and 2300° F. (1260° C.) can beused. The intent of this type of evaluation is to replicate theenvironment experienced in actual engines without having to perform thetest using an actual engine.

In the '176 patent, coating identified as Composition One had acomposition in weight percent of 3.0 cobalt, 24.3 chromium, 6.0aluminum, 0.1 yttrium, 0.8 hafnium, 1.5 weight percent silicon, 3.0tantalum, 6.0 tungsten, 0.0 rhenium, 0.0 molybdenum and the balancenickel. Substrates coated with Composition One had a relative absoluteoxidation life value using the same test of approximately 2.2. In otherwords Composition One has a functioning oxidation life that was morethan twice as long a functioning life as the base line uncoatedsubstrate.

A coating identified as Composition Two had a composition in weightpercent of 12.0 cobalt, 13.6 chromium, 6.1 aluminum, 0.0 yttrium, 0.8hafnium, 2.7 silicon, 3.5 tantalum, 2.8 tungsten, 1.5 rhenium, 0.8molybdenum and the balance nickel. Substrates coated with compositionTwo had a relative oxidation life value of approximately 1.4, or almosthalf again as long a functioning life compared to the baseline alloysubstrate against which it is compared.

Accordingly, by this test, the two tested compositions had oxidationlives exceeding that of the baseline, more particularly, at least 1.3times the baseline. Depending on conditions, preferred coatings may havesuch oxidation lives of at least 1.5 times the baseline or up to 2.5times the baseline if not more.

In the '176 patent, an additional method of assessing the oxidation lifeof a coating system is via cyclic furnace oxidation testing. ThisFurnace Cycle Oxidation Weight Change Measurement test was conducted,comparing the same uncoated Ni based superalloy substrate with asubstrate coated with Composition One as set forth above. In this test,specimens of each were raised and lowered into an air furnace, with thefurnace maintained at the same temperature for all of the tests. No jetfuel was used. After a certain number of cycles, the specimens wereremoved, and weighed and the data recorded. Cycling the same specimenswas resumed.

The uncoated Ni based superalloy substrate lost considerable weightafter a relatively few cycles. Specifically, the uncoated superalloysubstrates lost 65 mg/cm² in 100 cycles. Substrates coated withComposition One only lost 8 mg/cm² in over 360 cycles. This is asignificant improvement in oxidation resistance showing that theaddition of the coating increases the oxidation durability of thecomponents, thus, allowing parts to be in service for substantiallylonger periods of time. Thus, by this test, material loss may be reducedby an exemplary at least 50%, more particularly, at least 75% relativeto the baseline.

In the '176 patent, a corrosion test was performed. The test comprisedtaking a selected number of samples, exposing them to a salt solution,placing them in the elevated temperature in a static air furnace,without jet fuel or other combustion materials, for a period of time,such as a full day. Other time periods of less than twelve hours to morethan thirty six hours can be used. The samples are removed, more saltsolution is applied, and the samples were reinserted in the environment.At selected periods of time, one of the samples were removed from thetest apparatus and the effects of corrosion were evaluated.

Substrates coated with Composition Two identified above were compared tothe standard uncoated second generation Ni based superalloy. Fourcoupons of each were subjected to this test. One of the four coupons wasremoved and evaluated at each of the times shown in Table II. Sampleswere metallographically prepared, and the depth of attack through thecoating was measured.

Presented below in Table II are the results of this test which was runat 1650° F. (899° C.)

TABLE II Hot Corrosion Test Depth of attack (mils (micrometers))Substrate with Time Uncoated Ni-based Composition Two (hours) superalloyCoating 25 0.9 (23)  0.5 (13) 100 2.3 (58)  0.5 (13) 500 5.6 (142) 2.0(51) 1000 9.8 (249) 2.7 (69)

As can be seen in Table II, the resistance of the coupons coated withComposition Two to hot corrosion was much greater, and was almost aseffective at 1000 hours as the uncoated superalloy at 100 hours. Thus,exemplary improvement may be characterized as having a greater time toachieve the same level of corrosion than the baseline does at 100 hours,more particularly, at least 50% more time or at least doubling ortripling or quadrupling.

The exemplary abrasive is a cubic boron nitride (CBN). Exemplary CBN isparticles of characteristic size 3.5 to 9 mils (0.09 to 0.23 mm). Theexemplary abrasive by weight quantity is between 2:1 and 1:2 relative tomatrix.

In a process of manufacture, sheets (plates) of the abrasive brazematerial are prepared by mixing the abrasive particles and the two alloypowders in desired weight ratio. The mixture is the mixture is thenpre-sintered into an essentially fully dense plate. Exemplary sinteringis by heating the mixture in a vacuum atmosphere at elevated temperature(e.g., 2100° F. to 2300° F. (1149° C. to 1260° C.)) for exemplary timesof 1-10 hours. The sintering does not fully homogenize the alloy but maycause inter-diffusion at boundaries between particles of the two alloys.For example, it may create a near homogeneous alloy with discrete lowmelting areas. This is effective to leave particles of the low meltalloy with sufficient quantity of the melting point suppressant to bondthe prealloyed mixture to the substrate at a later stage in theprocessing.

Preforms may then be cut (e.g., laser cut or water jet cut) from thesheet. In the blade tip example, these may have airfoil-shapedfootprints/planforms (or planforms formed as perimeter portions ofairfoil shapes for tips having squealer pockets).

The preforms may then be brazed to the substrates. Exemplary brazingcomprises applying the preforms with surfaces 32 supported atopsubstrate surface 22. The preforms may initially betemporarily/partially secured by one or more appropriate means. Forexample, a tack weld at one location along the perimeter may beeffective. Alternatively, an adhesive may be used. Such adhesive mayevaporate or melt away in subsequent heat. The exemplary brazing occurswithout the use of any additional flux or chemical treatment. Thesubstrates may then be heated (e.g., in a furnace) to a temperatureeffective to braze the preform to the substrate. Exemplary heating isaccomplished in a vacuum furnace or by induction heating. Exemplaryheating is at 2100° F. to 2300° F. (1149° C. to 1260° C.) for a periodof at least one minute, more particularly, an exemplary 5-10 minutes. Ashort time above the solidus of the pre-alloyed plate will allow hightemperature diffusion braze bonding of environmental resistant brazematrix. This may allow a sufficient quantity of the melting pointsuppressant to bond and diffuse the prealloyed mixture to the substrate.

FIGS. 2 and 3 show alternate preforms 100 and 120 wherein the layer 30described above is an outer layer of a multi-layer preform.

In FIG. 2, the layer 30 is atop a base layer 130 having an inboardsurface or face 132 and an outboard surface or face 134. The base layercomprises a self-braze mixture as discussed above for the matrix 40 butlacking embedded abrasive.

The base layer thickness is shown as an essentially constant T₂.Exemplary T₂ is 0.25 mm, more broadly 0.20-2.5 mm or 0.20-1.0 mm. Suchthickness T₂ may be chosen so as to bond to the substrate and provideenvironmental protection. Thicker values may serve for dimensionalrestoration (e.g., when tip substrate is worn). In this embodiment, T₁may be similar to or less than the exemplary FIG. 1 ranges. For example,Exemplary FIG. 2 T₁ is 0.25 mm, more broadly 0.20-2.5 mm or 0.20-1.0 mm.Such thickness T₁ may be chosen merely to provide the desired depth ofabrasive based upon planned wear rates and tolerances.

The two layers may be separately manufactured as discussed above andthen attached to each other. In one example, the sheets are attached toeach other. This may be done by tack welding followed by a furthersintering step effective to secure the two layers while still leavingthe base layer with sufficient low melt alloy to braze to the substrate.Brazing to the substrate may be as is with the FIG. 1 preform.Alternatively, the airfoil planforms may be cut from the two layersbefore the layers are secured to each other.

In FIG. 3, an intermediate layer 140 intervenes between the layer 30 andthe base layer 130 and has an inboard surface or face 142 and anoutboard surface or face 144.

The intermediate layer adds thickness. This added thickness may bedesired in a dimensional restoration situation wherein original/priorsubstrate material has been removed. The intermediate layer may be anon-braze material. As discussed further below, the intermediate layermay be formed of a nickel-base superalloy.

Exemplary alloys are as disclosed in U.S. Pat. No. 4,719,080 of Duhl etal., issued Jan. 12, 1988, and entitled “Advanced High Strength SingleCrystal Superalloy Compositions” and U.S. Pat. No. 6,007,645 of Cetel etal., issued Dec. 28, 1999, and entitled “Advanced High Strength, HighlyOxidation Resistant Single Crystal Superalloy Compositions Having LowChromium Content”, the disclosures of which patents are incorporated byreference herein as if set forth at length. Such alloy may be selectedfor high oxidation resistance and high strength.

The intermediate layer thickness is shown as an essentially constant T₃.Exemplary T₃ is 1.5 mm, more broadly 0.5-2.5 mm or 1.0-2.0 mm. Suchthickness T₃ may be chosen so as to provide dimensional restoration inaddition to strength and oxidation resistance.

In this FIG. 3 embodiment, exemplary T₁ may be similar to that of theFIG. 2 embodiment. Exemplary T₂ may be similar to or less than theexemplary FIG. 2 ranges. For example, the intermediate layer may providethe desired dimensional restoration and oxidation resistance and thebase layer may merely be thick enough to perform the braze function andprovide a small amount of accommodation of surface irregularities.Exemplary FIG. 3 T₂ is 0.25 mm, more broadly 0.10-0.50 mm or 0.15-0.40mm. Such thickness T₂ may be chosen so as to be sufficient to bind theabrasive in the matrix. Thicker matrix may allow multiple layers ofabrasive particles to improve life of abrasive.

In a process of manufacture, sheets (plates) of the intermediate layermaterial are prepared by casting. For example, they may be investmentcast as single crystal sheets. Assembly with the other layers may be asdescribed above. securing the preform to the substrate may be asdescribed above.

Several alternative embodiments involve pre-forming the airfoil or otherfootprint/planform shape of the intermediate layer material. In oneexample an elongate single crystal cylinder is cast a cross-sectioncorresponding to the desired footprint/planform. The cylinder is thensliced (e.g., water jet cut) to form a plurality of intermediate layerpieces. These may be assembled with braze material (e.g., also cut tothe desired footprint/planform) as in the aforementioned embodiment.

Yet other embodiments using the intermediate layer may dispose of oralter the base layer. For example, the base layer could be replaces witha conventional braze foil used to secure a two layer preform havinglayer 30 atop layer 140 to the substrate.

FIG. 5 shows a preform 320 according to U.S. application Ser. No.14/750,324 and FIG. 6 shows a preform 420 according to U.S. applicationSer. No. 14/750,415 cited above. The preform has a base layer 130 (withcomposition as discussed relative to matrix 40 but lacking the embeddedabrasive) having an inboard surface or face 132 and an outboard surfaceor face 134. As is discussed further below, the base layer is formed bya braze material. An abrasive layer 340 has abrasive particles 42 atleast partially embedded in a matrix 344.

In the preform 420, an intermediate layer 450 (e.g., such as describedfor intermediate layer 140) has an inboard surface or face 452 and anoutboard surface or face 454 and is between the base layer 130 andabrasive layer 340. The intermediate layer adds thickness. This addedthickness may be desired in a dimensional restoration situation whereinoriginal/prior substrate material has been removed.

The base layer thickness is shown as an essentially constant T₁₁.Measured thickness may be a mean, median, or modal value. The abrasivelayer matrix thickness is shown as an essentially constant T₁₂ (e.g.,allowing for variation adjacent abrasive particles). The intermediatelayer thickness is shown as an essentially constant T₁₃.

Exemplary T₁₁ is 0.25 mm, more broadly 0.20-2.5 mm or 0.20-1.0 mm. Suchthickness T₁₁ may be chosen so as to bond to the substrate and provideenvironmental protection. Thicker values may serve for dimensionalrestoration (e.g., when tip substrate is worn). Exemplary T₁₂ is 0.25mm, more broadly 0.10-0.50 mm or 0.15-0.40 mm. Such thickness T₁₂ may bechosen so as to be sufficient to bind the abrasive in the matrix.Thicker matrix may allow multiple layers of abrasive particles toimprove life of abrasive. Exemplary T₁₃ is 1.5 mm, more broadly 0.5-2.5mm or 1.0-2.0 mm. Such thickness T₁₃ may be chosen so as to providedimensional restoration.

The matrix 344 comprises an MCrAlY. Matrix material is chosen so toprovide oxidation resistance and corrosion resistance. An exemplaryMCrAlY is Ni/Co plating with Cr, Al, and Y. More particularly, anexemplary MCrAlY comprises, by weight 50-70% Ni and/or Co. The CrAlY maybe an exemplary 30-50%. Impurity or other levels of components arepossible. Of the Cr, Al, and Y, an exemplary proportion is 64-75% Cr,24-35% Al, and 1-3% Y. An exemplary narrower range is 67-73% Cr, 27-33%Al, and 1-2% Y.

The exemplary abrasive 42 is a cubic boron nitride (CBN). Exemplary CBNis particles of characteristic size 3.5 to 9 mils (0.09 to 0.23 mm). Theexemplary abrasive quantity is 20-40% volume percent relative tocombined abrasive and matrix 344.

In a process of manufacture, sheets (plates) of the intermediate layer450 (for the FIG. 6 embodiment) material are prepared by casting. Forexample, they may be investment cast as single crystal sheets.

For both the FIG. 5 and FIG. 6 embodiments, sheets (plates) of the brazematerial are prepared by mixing the powders in desired weight ratio andpre-sintering them into an essentially fully dense plate. Exemplarysintering is by heating a mixture in a vacuum atmosphere at elevatedtemperature (e.g., 2100° F. to 2300° F. (1149° C. to 1260° C.)) forexemplary times of 1-10 hours. The sintering does not fully homogenizethe alloy but may cause inter-diffusion at boundaries between particles.For example, it may create a near homogeneous alloy with discrete lowmelting areas. This is effective to leave particles of the low meltalloy with sufficient quantity of the melting point suppressant to bondthe prealloyed mixture to the substrate at a later stage in theprocessing.

The matrix and abrasive may be co-applied to the outboard surface (134for FIG. 5 or 454 for FIG. 6). Exemplary co-application is a platingprocess. Exemplary plating is a slurry plating in which discrete statesof abrasive, CrAlY, and nickel and/or cobalt (hereafter collectivelyNi/Co) are applied. This is followed by an interdiffusion discussedbelow. In one exemplary process, the plating is an entrapment platingprocess wherein the Ni/Co is used in one or more stages to entrapparticles of the other components. In one example, a first stageinvolves Ni/Co entrapment plating of a first amount of the CrAlY powderto the substrate. The second stage involves Ni/Co entrapment plating ofthe abrasive (e.g., CBN) atop the first plating. A third stage involvesNi/Co entrapment plating of a second amount of CrAlY powder around theabrasive particles applied in the second stage. The relatively largesize of abrasive particles compared with the CrAlY particles means thatthere will be a high degree of protrusion of the abrasive particlesapplied during the second stage compared with CrAlY particles appliedduring the first stage.

After plating, there may be a heat treatment to cause the diffusion toat least partially homogenize the MCrAlY and bond it to the brazematerial. Alternatively, this result may be achieved during the finalbonding. For the GFIG. 6 embodiment, the heat treatment may also be usedto bond the intermediate layer to the base layer. For example, the baselayer may be secure or otherwise held to the intermediate layer byadhesive or tack welding.

The exemplary heat treatment is to 1900° F. to 2000° F. (1038° C. to1204° C.). If performed, this heat treatment leaves the material of thebase layer 130 still having discrete low and high melt phases in orderto allow a sufficient quantity of the melting point suppressant to bondthe prealloyed mixture to the substrate at a later stage in theprocessing.

Preforms 320 or 420 may then be cut (e.g., laser cut or water jet cut)from the sheet. In the blade tip example, these may have airfoil-shapedplanforms (or planforms formed as perimeter portions of airfoil shapesfor tips having squealer pockets).

The preforms 320 or 420 may then be brazed to the substrates. Exemplarybrazing comprises applying the preforms with surfaces 32 supported atopsubstrate surface 22. The preforms may initially betemporarily/partially secured by one or more appropriate means. Forexample, a tack weld at one location along the perimeter may beeffective. Alternatively, an adhesive may be used. Such adhesive mayevaporate or melt away in subsequent heat. The exemplary brazing occurswithout the use of any additional braze alloy, flux, or chemicaltreatment. The substrates may then be heated (e.g., in a furnace) to atemperature effective to braze the preform to the substrate. Exemplaryheating is accomplished in a vacuum furnace or by induction heating.Exemplary heating is at 2100° F. to 2300° F. (1149° C. to 1260° C.) fora period of at least one minute, more particularly, an exemplary 5-10minutes. A short time above the solidus of the pre-alloyed plate 130will allow high temperature diffusion braze bonding of environmentalresistant braze while not affecting the plated CBN/MCrAlY matrix or thesingle crystal layer 450. This allows more preferred/durable chemistriesto be for the braze material. This may allow a sufficient quantity ofthe melting point suppressant to bond and diffuse the prealloyed mixtureto the substrate without affecting the structure of the plated CBN inMCrAlY matrix.

Several alternative embodiments relative to the FIG. 6 embodimentinvolve pre-forming the airfoil or other footprint/planform shape of theintermediate layer material. In one example an elongate single crystalcylinder is cast having a cross-section corresponding to the desiredfootprint/planform. The cylinder is then sliced (e.g., water jet cut) toform a plurality of intermediate layer pieces. These may be assembledwith braze material (e.g., also cut to the desired footprint/planform)as in the aforementioned embodiment. The matrix and abrasive may beapplied as above either before or after the bonding.

The use of “first”, “second”, and the like in the following claims isfor differentiation within the claim only and does not necessarilyindicate relative or absolute importance or temporal order. Similarly,the identification in a claim of one element as “first” (or the like)does not preclude such “first” element from identifying an element thatis referred to as “second” (or the like) in another claim or in thedescription.

Where a measure is given in English units followed by a parentheticalcontaining corresponding SI or other units, the parenthetical's unitsare a conversion and should not imply a degree of precision not found inthe English units.

One or more embodiments have been described. Nevertheless, it will beunderstood that various modifications may be made. For example, whenapplied to an existing baseline configuration, details of such baselinemay influence details of particular implementations. Accordingly, otherembodiments are within the scope of the following claims.

What is claimed is:
 1. An abrasive braze preform comprising: aself-braze layer; and a matrix at least partially embedding an abrasive,wherein: the self-braze layer comprises a sintered sheet of: at leastone first alloy; and at least one second alloy of high melting pointrelative to the first alloy; the at least one first alloy comprisesabout 21.25-22.75 chromium, about 5.7-6.3 aluminum, about 11.5-12.5cobalt, about 5.7-6.3 silicon, boron in an amount no greater than 1.0weight percent, and a balance of nickel plus impurities if any; and theat least one second alloy comprises about 4.75-10.5 chromium, about5.5-6.7 aluminum, up to about 13 weight percent cobalt, about 3.75-9.0tantalum, about 1.3-2.25 molybdenum, about 3.0-6.8 tungsten, about2.6-3.25 rhenium, up to about 0.02 boron, about 0.05-2.0 hafnium, up toabout 0.14 carbon, up to about 0.35 zirconium, and a balance of nickelplus impurities if any.
 2. The preform of claim 1 further comprising: anintermediate layer between the matrix and the self-braze layer.
 3. Thepreform of claim 2 wherein: the intermediate layer is a pre-cast layer.4. The preform of claim 2 wherein: the intermediate layer is diffusionbrazed to the self-braze layer.
 5. The preform of claim 1 wherein: thematrix is an MCrAlY.
 6. The preform of claim 5 wherein: the matrix is aplating.
 7. The preform of claim 5 further comprising: a cast singlecrystal intermediate layer between the matrix and the self-braze layer.8. The braze preform of claim 7 wherein the self-braze layer comprises asintered mixture of: at least one first alloy; and at least one secondalloy of high melting point relative to the first alloy.
 9. The brazepreform of claim 5 wherein the self-braze layer comprises a sinteredmixture of: at least one first alloy; and at least one second alloy ofhigh melting point relative to the first alloy.
 10. The preform of claim9 further comprising: the matrix is a plating.
 11. An abrasive brazepreform comprising: a self-braze layer; and a matrix at least partiallyembedding an abrasive, wherein: the matrix is an MCrAlY; and the preformfurther comprises a cast single crystal intermediate layer between thematrix and the self-braze layer.
 12. The preform of claim 11 wherein:the matrix is a plating.
 13. The braze preform of claim 11 wherein theself-braze layer comprises a sintered mixture of: at least one firstalloy; and at least one second alloy of high melting point relative tothe first alloy.